Binder material for coal, coke, and the like, and the manufacture thereof



Patented Nov. l, 1932 UNITED L'UDWIG KER-N AND FERNANDO G. KERN, F WEBSTER GROVES, MISSOURI BINDER MATERIAL FOR COAL, COKE, AND THE LIKE, 'AND' THE MANUFACTURE THEREOF No Drawing.

This invention relates to binder materials for pulverized'coal, coke and the like, and with regard to certain more specific features, to non-smoke producing binder materials.

Among the several obj cts of the invention may be noted the rovisi n of a binder material of non-smo e producing characteristicswhich is made from readily obtainable material normally discarded at coal mines; a binder material which is readily adaptable to varieties of coal with beneficial results; a binder material which, when utilized with coal, coke and the like, produces a bound product of high compressive strength unusual hardness and wear-resistir g quahties; the production as a by-product of a highly useful decolorizing and deodorizing pulver ized filtering material; and the provision of a process for manufacturing a binder material of the class described which is easily and economically carried through, and which requires a minimum of expensive treating materials and the like. Other objects will be in part obvious and in part pointed out hereinafter.

. form unsatisfactory coke of low compressive strength, low. wear-resisting qualities, and the li (e It has been proposed to use binder materials, suchas liquefied asphalt, pitch, tar, oils, naphthalene, or resins, in order to bind the coal into satisfactory lumps for coking. In general these binder materials are only partially satisfactory, and do not lead to a hard coke. Additional disadvantages include the predominant smoke-pro- F ducing characteristics of such binder mate rials, which render the product unfit for commercial utilization in large cities and the like.

The present invention provides a binder material for non-coking coals which binds said coals to effect a hard, firm coke as here- 1930. Serial No. 462,128.

inbefore described, and which is not smokeproducing in its characteristics.

Ordinary bituminous coal exists in geologic strata which are imbedded' in and interspersed with clays, shales, and other earthy materials, generally termed coal shales or gangue material. This gangue material in general comprises hydrates, oxides, carbonates, and silicates of aluminum, calcium, magnesium, sodium and iron. Impurities are variable; contents of silicia, sand, pyrites, and organic or carbonaceous materials are not uncommon.

This gangue material, not necessarily cleaned or freed of its carbonaceous adher- The solid residue is washed and passed through a filter press.

The supernatant liquid comprises a concentrated, viscous solution of the chlorides of the metals forming the gangue material. In general, the principal constituents are aluminum, calcium, magnesium, sodium, and iron chlorides, and free hydrochloric acid. This liquid constitutes a valuable binder and plasticizer material forcomminuted coal, whereby it can be formed into briquettes and eflectively coked. The solution presumably functions as a binder material by reacting with and plasticizing the ash-forming constituents of the coal- It is to be understood that the supernatant liquid may be concentrated or diluted, as individual cases may require.

The solid material left behind after the supernatant liquid has been decanted is preferably washed until only faintly acid, passed through a filter press, and dried and powdered. The powder in general comprises hydrochloric acid-insoluble materials, together with residues of unattacked acid-soluble ma terials, and carbonaceous matter. The powder is a valuable decolorizing and deodorizing agent to oils, fats, waxes and the like, and a filter material for natural and synthetic dyes, especially of an alkaline nature.

It is to be understood that, if desired, the acid solution need not be decanted, but may be used as a binder material with the undissolved residue still therein. I

; coal.

A specific example of the invention is as follows:

Illinois coal mine clay is ground to a fineness of from 100 to 200 mesh, and treated in a clay washer to remove silica, sand, pyrites and gob. The washed clay is then mixed with from 50 to 100 per cent. by wei ht of aqueous hydrochloric acid of gravity 1% B. The mixture is boiled at about 100 C. for two hours or more, preferably with constant agitation. Water and/or more acid is added from time to time to keep up the proper volume. After the boiling is completed, the mixture is allowed to settle, and the supernatant solution drawn off or decanted. This solution is preferably then diluted to a grav ity of the order of 4 to 6 B., in which condition it is used for plasticizing comminuted The solid matter left after the decantation comprises about 70 per cent. silica, 4 per cent. iron oxide, 6 per cent. alumina, and the remainder carbonaceous materials and impurities. It is washed until the wash water shows only a slight acid reaction on litmus paper, then filtered and dried at temperatures not higher than the order of 85 C., and pulverized.

In view of the foregoing, it will be seen that the several objects of the invention are achieved and other advantageous results attained.

As many changes could be made in carrying out the above objects without departing from the scope of the invention, it is intended that all matter contained in the above description shall be interpreted as illustrative and not in a limiting sense.

We claim 1. A binder material for pulverized coal and the like comprising an acid solution of coal gangue containing an excess of acid.

2. A binder material for pulverized coal and the like comprising a hydrochloric acid solution of coal gangue containing an excess of hydrochloric acid.

3. A binder material for pulverized coal and the like comprising a solution of the chlorides of metals present in coal gangue containing free hydrochloric acid.

4. A binder material for pulverized coal and the like comprising a hydrochloric acid solution of earthy materials containing free hydrochloric acid.

5. The process of manufacturing a binder material for pulverized coal and the like which comprises comminuting the gangue material ordinarily naturally associated with said coal, treating the pulverized gangue with hydrochloric acid whereby various con-- stituents of said gangue are dissolved, and removing said acid with the substances dissolved therein from the undissolved gangue..

6. The process of manufacturing a' binder material for pulverized coal and the like which comgfises comminuting the gangue material or narily naturally associated with said coal, boiling the pulverized gangue with hydrochloric acid whereby various constituents of said gangue are dissolved, and removper cent. of its weight of hydrochloric acid,

whereby portions of said gangue are dissolved in said hydrochloric acid and removing said hydrochloric acid solution from the undissolved portion of said gangue.

8. The filter material which comprises comminuted coal gangue from which a substantial portion of the metallic constituents have been dissolved with hydrochloric acid.

'9.--The filter material which comprises comminuted coal gangue which has been treated with hydrochloric acid for the removal-of a substantial portion of the metallic constituents.

10. The filter material which comprises a comminuted mixture of approximately 70% silica, 4% iron oxide, 6% alumina, and the remainder carbonaceous material.

In testimony whereof, we have signed our names to this specification this 13th day of June, 1930.

LUDWIG KERN. FERNANDO C. KERN. 

